Method of and apparatus for manufacturing tiles



E. H. WHITE Sept. 10, 1929.

METHOD OF AND APPARATUS FOR MANUFACTURING TILES Original Filed May 20.1926 2 Sheets-Sheet amvemfoz E. H. WHITE Sept. 10, 1929.

METHOD OF AND APPARATUS FOR MANUFACTURING was 7 Original Filed ma 20,1926 2 Sheets-Sheet 2 gmvewtoz 315 atfozmu Patented Sept. 10, 1929.

UNITED STATES PATENT OFFICE.

METHOD OF AND APPARATUS FOR MANUFACTURING TILES.

Application filed May 20, 1926, Serial No. 110,343. .Renewed November30, 1928.

This invention relates to the manufacture of tiles and more particularlyto a method of and an apparatus for manufacturing multicoloreddecorative tiles. Tiles are qulte extensively used in the buildingtrades for many purposes. A great majority of all tiles now being usedare ceramic'in nature, which are finished and hardened by firing orburnlng. Burned tiles are expensive and often deteriorate with age.Further, there are many limitations upon the character and colors oftiles which may be made by firing.

The primary object of the present nvention is to provide a method bywhich tiles of excellent quality and hardness and great beauty may bemade with naturally hardening cementitious materials.

Another object of the invention is to provide a method by'which tilesmay be made 2 very hard and heat proof and provide tile surfaces whichwill not check or readily deteriorate with age.

A further object of the invention is to provide a method of andapparatus for making multi-colored decorative tiles of uniform qualityand pleasing color effects.

Vitlr these and other objects in view the invention consists in themethod of and apparatus for making decorative tiles hereinafterdescribed and particularly defined in the claims.

The various features of the invention are illustrated in theaccompanying drawing, in which:

Fig. 1 is a view in side elevation with parts broken away of anapparatus in which the method of making decorative tiles in accordancewith the preferred form of the invention may be carried out;

in Fig. 1 and taken on the line 22.of Fig. 1;

Fig. 3 is a vertical sectional view of a feed hopper of the apparatustaken on the line 3--3 of Fig. 4; v

Fig. 4 is the front elevation of the feedhopper. and

Fig. 5 is a side elevation of one of the Vibrators used in theapparatus. 1

The apparatus shown in the drawings is designed primarily for carryingona continu- Fig. 2 is a plan view of the apparatus shown,

ous manufacture of tiles while developing any desired multi-coloredeffect of a substantially uniform nature. The preferred method of makingtiles with the apparatus shown in the drawings consists in passing formsunder feed hoppers and depositing in the forms layers of plasticmaterials, each layer consisting of one of the characteristic colorsused in se curing the color effect of the finished tile. After thedesired number of layers have been built up in the forms they areconveyed beneath vibrating apparatus, and a series of differentvibrations are imparted to the forms to compact the cementitiousmaterial in the form and to carry the colors of the different 65 cementthrough the various layers to bring out various color designs on thefaces of the tiles which are at the bottoms of the forms. The vibrationsare carried on in successive stages, the first stage being comparativelyslow rate of vibration, the next stage-having a higher rate ofvibration, and the last stage imparting the highest rate of vibration.The plastic cementitious materials in the layers are forced through oneanother while in a plastic state and after theform has been sufficientlyvibrated to develop the desired color effect. the form is deposited in acuring room and the tile allowed to harden to give the finished product.

The above described method may be carried out in the apparatusillustrated in the drawings as follows:

A cementitious material each with a different color is supplied to feedhoppers 10, 85 12, 14, and 16. The cement passes through a slot 18 atthe bottom of each hopper to feed aprons 20, 22', 24, and 26. The cementis uniformly distributed over the aprons 20 to 26 by vibration and flowsunder a doctor 28 where the thickness of the layer may be carefullygauged to deposit any desired thickness of cement in the form. The formfor receiving the cement illustrated in Fig. 3 consists of a flat opentop box which moves on guide rails 30 which are in the form of angleirons and spaced apart a distance substantially equal to the width ofthe form. The forms are carried along the guide rails 30 by means ofconveyer chains 32, Fig. 4, which are'pro- 100 vided with upstandinglugs 36 arranged to engage the rear edge of the form. As the form passesunder the hopper the doctor 28 is lifted and a stream of cement isdeposited in a layer inthe form. The apron has a width substantially'equal to the width of theform and therefore the cementitious layer isdeposited in a substantiall uniform layer in the form. As shown in t edrawing the doctor 28 is arranged to be manually operated to feed thecementitious material to the form while it is passing thereunder; butautomatic means may be used which ma be operated by the form to open andclose t e doctor in depositing the layer in the form. As the form passesalong under the succeeding hoppers, successive layers of materials arebuilt up in the form and the loaded form then passes under a series ofvibrators 38, 40, 42 and 44.

The vibrators consist of hammers 46, Fig. 5, which are arranged toengage opposite edges of the form. The hammers 46 are carried on a head48 which in turn is movably mounted in a' frame 50. In the frame 50 ismounted a roller 52 which is arranged to engage a cam 54 and a rotationof the cam imparts a vibration to the frame. The hammers 46 permit theform to move thereunder and impart a continuous vibration to the form asit advances. The vibrator38 has the lowest speed of vibration andvibrators 40, 42 and 44have successively increasing rates of vibration.After the forms pass under the vibrator 44 they are removed from theguide rails and sent to a conditioning room to harden.

The cement hoppers have all substantially the same construction and modeof operation and are illustrated in detail in Figs. 3 and 4. Each hopperconsists of a box-like structure 56 having a downwardly inclined bottom58. The bottom feed spout 18 is provided with a rod 60 and a gate 62.The rod 60 is adjustable on the set screws 64 to assist in providing aslot of any desired opening. The gate 62 has the form of a roller whichis eccentrically mounted on pins 66 located on each end of the roll. Thepins 66 are arranged to clamp the gate in any desired position and theeccentric mounting of the gate permits an adjustment of the opening ofthe slot 18. The hopper 56 is arranged to move between guides 68 securedto a framework 70, the hopper being supported by hangers 72. The hangers72 are shown more particularly in Fig. 4 and consist of arms 74 whichare attached to the sides of the hopper and cross bars 76 connecting thearms. A wear plate 7 8 is mounted upon the bottom of each of the bars 76 and is arranged to engage eccentrics 80 which are fixed on a driveshaft 82. The drive shaft is rotatably mounted in journals 84 mounted onthe frame and rotary motion is imparted to the camsby means of a belt 86which runs over a fixed pulley 88. A loose pulley 90 is mountedadjacentthe fixed pulleys 88 by which the belt may be moved into an idlerosition when the hoppers are, not in use. he eccentric mounting of thehopper on the eccentric 80 im arts a vibration to the hoppers which tens to mix and move-the plastic cement downwardly through the hopper andthrough the feed slot 18.

The feed aprons 20, 22, 24 and 26 have all the same construction andmode of operation and are illustrated in detail in Figs. 3 and 4. Eachapron is mounted directly below the hopper 56 and is preferably madewith a delivery edge of substantially the width of the tile form. Thecementitious material issuing from the feed slot 18 is deposited on theupper end of the apron behind a dam 92. The cement moves .through anopening between the bottom of the dam .92 and the apron downwardlyacross the apron and into engagement with the doctor 28. The doctor 28is arranged to be moved toward and from the apron by means of a bellcrank lever 94. The a'pron is mounted on a' framework 98 which isarranged to have a pivotal mounting around pins 100. The front end ofthe frame 98 is yieldably held against the pins 100 by means of a bolt102 and a spring 104. The back end of the frame 98 is yieldingly mountedin a frame 70 by means of a bolt 106 and a spring 108. A yieldableconnection is made between the upper part of the apron frame and thebottom of the hopper consisting of a bolt 110 and a spring'112. Thevibration imparted to the hopper is imparted through the spring 112 tothe apron frame and the mounting of the frame tends to give a vibrationto the apron that will distribute and feed the cement over the face ofthe apron. The adjustment of the doctor with reference to the apron willdetermine the thickness of the layer of cement which runs over the apronunder the form.

The apparatus for imparting vibration to the tile forms is illustratedmore particularly in Figs. 1 and 5. Each vibrator has substantially thesame construction and the different speed of vibration of each of thevibrators 38 and 44 inclusive is obtained preferably by using electricmotors having different rates of rotation. It is obvious that the ratesof vibration may be varied by different size of gearing connectionsbetween the driving motor and the eccentric which imparts vibration tothe vibrating hammers. Referring to Fig. 5, the hammers 46 areadjustably mounted on the head 48 by means of a series of lock nuts sothat the normal spacing of the hammers from the top of the form may bevaried. The frame 50 which carries the head 48 is slidably mounted in aguide 114 in a framework 116. Slots 118 are formed in the frame 50 whichare arranged to re ceive a shaft 120 on which the eccentric .54 isfixed. The shaft 120 is mounted in bearings 122 and a driving gear 124is fixed on the shaft. A belt 126 passes from thepulley 124 to a pulley128 mounted on the shaft 130 of an electrically driven motor 132.

The vibrating devices illustrated in the drawings are arranged to give avertical vibration to the hammers to strike the top of the form. Othervibrating hammers may be provided which may impart vibration to thebottom or sides of the form. It has been found that different formsv ofvibration vary the nature of the tiles and the character of the coloringeffect which may be obtained. It

has been found moreover, that the rate of vibration and the manner inwhich the different rates of vibration are imparted has a very markedeffect upon the product; that is, at vibrations from 3000 to 8000impulses per minute very remarkable effects as to coloring and densityhave been produced. In the manufacture of the ordinary forms of tileshowever the rates of vibration varying from to 2000 impulses per minutehave been found to be very satisfactory. The higher rates of vibrationtend to compact the material and give very hard, fine grained blocks.The vibration furthermore, tends to bring'the larger particles and thoseparticles of the lowest gravr' W to the top of the form.

One important feature of the invention consists in the use of differentcolors of cementitious materials in order to get the desired coloringeffects for the finished tiles. This coloring effect is obtained bymixing an individual cementitious material for each color and carefullyregulating the specific gravity of the cement, the water consistency ofthe cement, the order of the distribution of the different colors oflayers in the form, and the nature of vibration imparted to the formcontaining the cement layers. A hopper is provided for ea'ch cement ofeach color and each one of the cements of the various colors isdeposited in a layer in the form in which the tile is to be made. Thecement having the lightest specific gravity is preferably deposited inthe bottom of the form and the cement of the heaviest specific gravityis preferably deposited on the top layer in the form. Different kinds ofcoloring effects may be obtained by reversing the order of the specificgravities of the cement layers from that described above and by otherorders of arrangements of the cement layers. The vibration imparted tothe cement by the hammers travels through the cementitious materials ina radial path. The cementitious material of the lowest specific gravityfollows a generally upward path and the cementitious material of thehighest specific gravity moves in a generally downward path. If thevibration is continued for a suflicient length of time, substantiallyall of the heavy cement may be moved to the bottom of the form, andsubstantially all of the lightest cement may be moved to the top of theform. It will be apparent therefore that if the material is deposited inuniform layers and each form is vibrated at substantially the same rateand for the same period of time, the color designs and figurations ofthe. tile will be substantially uniform. That is, the designs will notagree in contour, but the general appearance and color effects will besubstantially umform so that they may be used inbuilding up a floor orside Wall and give a very pleasmg and uniform appearance. Other coloringeffects may be obtained by varying the density or water consistency ofthe layers and by building the layers partly of wet cement and partly ofdry. cement.

Incarrying out the preferred form of the invention all of the cements ofthe various different colors are preferably made up with onecementitious base, that is a base of Portland cement, of lime,magnesite, or magneslum oxide. In making some very satisfactory tiles 2.series of different cements have been made, each having a differentcolor which consist of substantially 50% mag nesium oxide and theremainder being rock fillers of different colors and different specificgravities. In case it is intended to impart great hardness and have aproduct of high density, a retarder is used with the cements to retardthe setting and assist the movement of the different color layers ofcements through one another.

In the drawing four feed hoppers and four vibrators have beenilllstrated. It is obvious that the number of the hoppers and thevibrators may be varied in accordance with the colors to be desired. Theapparatus operates continuously and can be made entirely automaticif'desired.

The preferred form of the invention having been thus described what isclaimed as new is:

1. A method of forming tiles having deco rative surface designscomprising arranging a series of layers of plastic cements of differentcolors in a form and forcing portions of the cements from the differentlayers to penetrate through one another to the bottom of the tile whilein a soft plastic condition by imparting rapid vibration to the formcarrying the cements.

2. A method of forming tile having decorative surface designs comprisingarranging a series of layers of plastic cement containing rock fillersof different characters and substantial ronortions of magnesium oxide,in a form and forcing the cements of portions of the different layers topenetrate through one another to the bottom of the form while in aplastic condition by imparting rapid vibration thereto.

3. A method of forming tiles comprising arranging a series of layers ofplastic cements of different specific gravities in a form, the cement ofthe lowest specific gravity being placed in the bottom of the form, andthe lay- 4 ers of the heavier specific gravities being placed in remotePOSltlOILfI'OlII the bottom of the form in the order of their specificgrav1 ties, and forcing the cements of different lay ers to penetratethrough one another while in a plastic condition by imparting rapidvibration thereto. 4. A method of forming tiles comprising arranging aseries of layers of plastic cements, containing substantial proportionsof magnesium-oxide mixed with rock fillers of different specificgravities and colors, in a form, the layers of the heaviest specificgravities being placed most remote from the bottom of the form,'andcausing the cement of the d fferent layers to penetrate through oneanother while in a plastic condition by imparting a rapld vibrationthereto. 7 5. A method of forming tiles comprising arranging a series ofbodies of plastic cements of different specific gravities and colors ina form, forcing the cements from the different bo'dies to penetratethrough one another while in a plastic condition by imparting a rapidvibration thereto, and varying the character of the design and theextent of the penetration of the layers by the control of thevibration.

6. A method of forming tiles comprising arranging a series of bodies ofplastic cements of different specific gravities and colors in a form,forcing the cements from the different bodies to penetrate through oneanother while in a plastic condition by imparting a rapid vibrationthereto, and varying the character of the design and coloring effect ofthe finished tiles by varying the arrangement of the bodies in the formbefore starting the vibration of the tile.

7. A method of forming tiles comprising arranging a series of bodies ofplastic cements of different specific gravities and colors in a form,forcing the cements from the different bodies to penetrate through oneanother while in a plastic condition by imparting a rapid vibrationthereto and varying the character of the design and coloring effect ofthe tile by varying the water consistency of the cement bodies.

8. A method of forming tiles comprising placing the plastic cement in aform and compacting the cement and controlling the. set thereof bysuccessively imparting different vibrations for substantial periods oftime, the vibration of each succeeding period increasing in the rate ofvibration.

9. A method of forming tiles comprising placing plastic cement in aform, continuously advancing and simultaneously imparting vibration tothe form, and increasing the rate of vibration as the form advances.

10. method of forming titles comprising arranging a series of layers ofcement while in plastic condition and of different specific gravitiesand colors in a form, continuously advancing the form while vibrating itand controlling the vibrations to impart an increasing speed ofvibration as the form advances.

11. A method of forming tiles comprising continuously advancin a formunder containers of cement of different gravities and colors, passingsuccessive layers of substantially uniform thickness from the containersto the forms as the forms advance, vibrating the forms after the layershave been deposited therein, and varying the speed of vibration of theforms as they advance.

12. A method of forming tiles comprising continuously advancing a formunder containers of cement of different gravities and colors, passingsuccessive layers of substantially uniform thickness from the containersto the forms as the forms advance, vibrating the forms after the layershave been deposited therein, and controlling the feed and distributionof cements into the forms by vibration of the cement containers.

13. A method of making tiles comprising arranging a series of bodies ofplastic cements, each body containing approximately 50% of magnesiumoxide and rock fillers, each body having a different rock filler and adificrent color, the bodies of the highest specific gravity being placedmost remote from the bottom of the form, and forcing the bodies topenetrate through one another by imparting a series of vibrations to theform and increasing the rate of vibration of the succeeding vibrations.

14. An apparatus for forming tile coming apron for each hopper arrangedto pass a sheet of plastic material from the hopper upon forms movablewith the conveyer, a series of vibrators mounted adjacent the conveyerhaving members arranged to engage the forms on the conveyer, and meansto op erate said vibrators at different rates of vibration.

16. An apparatus for forming tile comprising a conveyer, a series ofseparate hoppers mounted above the conveyer, a distributing apron foreach hopper arranged to pass a sheet of plastic material from eachhopper upon forms movable with the conveyer, a series of vibratorsmounted adjacent the conveyer having members arranged to engage theforms on the conveyer, and means to operate said vibrators at differentrates of vibration, the rates of vibration increasing in the directionof the advance of the conveyer.

17. An apparatus for forming tile comprising a conveyer, a series ofhoppers mounted above the conveyer, a distributing apron for eachhopper, means to vibrate the hoppers to distribute plastic material overthe aprons, forms movable With the conveyer under the aprons, and aseries of vibrators mounted adjacent the conveyer and arranged tovibrate forms on the conveyer.

18. An apparatus for forming tile compristhereon, a series of hoppersmounted over said track, each hopper having an apron of approximatelythe width of the form, means to feed a sheet ofplastic material fromsaid hoppers to the forms and a series of vibrators mounted adjacent thetrack in the rear of the said hoppers and arranged to engage the form onthe track and means for operating the vibrator and conveyer.

20. 'A method of forming tiles having decorative surface designscomprising arrang-. ing a series of layers of cements of difierentcolors containing a binder and a filler in a form, forcing portions ofthe cement from the different layers to penetrate through one another tothe bottom of the form by'imparting a vibration to the form, andtreating the formed tiles to harden the cement.

21. A method of forming tiles having decorative surface designscomprising arranging a series of layers of cements of different colorsin a form, said cements containing a binder and filling material ofdifferent colors, forcing portions-of the different colored cements topenetrate through one another to the base of the tile in the form byimparting rapid vibration of the form and then treating the formed tileto harden the cement;

In testimony whereof I aflix my signature.

EDWIN H. WHITE.

